WO2010150173A1 - Junction module of building integrated photovoltaic system - Google Patents

Junction module of building integrated photovoltaic system Download PDF

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Publication number
WO2010150173A1
WO2010150173A1 PCT/IB2010/052792 IB2010052792W WO2010150173A1 WO 2010150173 A1 WO2010150173 A1 WO 2010150173A1 IB 2010052792 W IB2010052792 W IB 2010052792W WO 2010150173 A1 WO2010150173 A1 WO 2010150173A1
Authority
WO
WIPO (PCT)
Prior art keywords
junction module
conductive
housing
connection
cavities
Prior art date
Application number
PCT/IB2010/052792
Other languages
French (fr)
Inventor
Feng Wang
Rojay Chen
Chunfu Zhou
Original Assignee
Tyco Electronics (Shanghai) Co. Ltd.
Tyco Electronics Uk Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tyco Electronics (Shanghai) Co. Ltd., Tyco Electronics Uk Ltd filed Critical Tyco Electronics (Shanghai) Co. Ltd.
Publication of WO2010150173A1 publication Critical patent/WO2010150173A1/en

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Classifications

    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02SGENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/30Electrical components
    • H02S40/34Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02ATECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00Adapting or protecting infrastructure or their operation
    • Y02A30/60Planning or developing urban green infrastructure
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02BCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00Integration of renewable energy sources in buildings
    • Y02B10/10Photovoltaic [PV]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/50Photovoltaic [PV] energy

Definitions

  • the present invention relates to the field of the building integrated photovoltaic (BIPV) technology, more particularly, to a junction module for building integration photovoltaic system.
  • BIPV building integrated photovoltaic
  • Solar energy is a kind of renewable energy source. Converting solar energy into electricity could save the resource of energy and mitigate increasing demands in power supply, and reduce the environment pollution as well. Therefore, this technology receives much attention and interest from the public.
  • the solar cell assembly photovoltaic assembly
  • the solar cell assembly is mounted on the accomplished roof through a support, and a junction module to cooperate with the assembly is usually disposed at the backside of the solar cell assembly.
  • BIPV building integrated photovoltaic technology
  • connection terminal (lug) extending from the photovoltaic element of the solar cell assembly typically forms electrical connection with the conductive element of the junction module through soldering, and afterwards, a sealant is applied to achieve sealing.
  • the electrical connection between the connection terminal (lug) from the solar cell assembly and the conductive element of the junction module is formed by soldering, which requires much operation time, decreases the reliability and rate of the qualified finished product, and thus results in high production cost, due to the complexity of the soldering;
  • the connection formed by soldering is a permanent connection, it is hard to remove the solar cell assembly from the junction module, and vice versa;
  • the above junction module is usually in a form of a long and narrow cavity, and a long and narrow cover is commonly provided to close the cavity for replacing or removing internal elements in the junction module, however, since the cavity and the cover are long and narrow, it is difficult to manufacture the junction module, which also results in low production efficiency, and since one long and narrow cover is used to close the whole cavity, it is not convenient to replace the internal elements of interest individually.
  • an object of the present invention is to provide a junction module of a building integrated photovoltaic system which can be easily mounted and removed.
  • Another object of the present invention is to provide a reliable junction module of building integrated photovoltaic system which can be produced with high production efficiency.
  • a further object of the present invention is to provide a junction module of a building integrated photovoltaic system, internal elements of interest inside which can be replaced conveniently.
  • a junction module of building integrated photovoltaic system comprises: a housing having at least one opening, the at least one opening being provided in a surface of the housing for inserting lugs electrically connected with the positive and negative electrodes of a solar cell panel; a first and a second conductive member accommodated in the housing, the first and second conductive members being electrically connected with the lugs respectively through first resilient clips; and a bypass diode connected between the first and second conductive members, wherein the housing comprises a plurality of cavities, and wherein among the bypass diode and the first, second conductive members, at least one of which is provided separately in different cavities.
  • each of the plurality of cavities has an opening
  • the junction module further comprises a plurality of covers each of which closes the corresponding opening in a detachable manner.
  • the junction module further comprises seal rings each provided between the cover and the corresponding opening so as to form a seal therebetween.
  • At least one end of the housing is formed as a close end, or is formed as an opening end having an outlet hole for connecting with an external cable directly or via a cable connector.
  • the external cable may be electrically connected, at the opening end, with at least one of the first and second conductive members in a detachable manner.
  • the junction module further comprises a second clip constructed to clip together a core of the external cable and at least one of the first and second conductive members, and the second clip together with the at least one of the first and second conductive members are provided together in one of the plurality of cavities.
  • the first and second conductive members comprise first and second conductive rails and connection conductors, the connection conductors comprising two opposite sides which are substantially flat surfaces; and the first resilient clip with a cross section which substantially forms a triangle having an opening on top, comprising a bottom wall and two sidewalls extending from the bottom wall at two sides of the bottom wall at an acute angle, wherein when the first resilient clip clamps the lug, the two opposite sidewalls of the clip contact with the lug and apply a bias force to the lug so that a stable electrical connection between the lug and the connection conductor is formed.
  • first and second connection conductors extend from the first and second conductive rails respectively and form integrally with the corresponding conductive rails.
  • the first and second conductive rails are further provided with securing springs by means of which two pins of the bypass diode are electrically connected with the first and second conductive rails.
  • the above detachable manner is carried out by at least one of clasp connection, bolt connection, screw connection, stud connection and hinge connection.
  • the housing comprises two cavities, and the bypass diode and one of the first and second conductors are provided in one cavity, while the other of the first and second conductive members is provided in the other cavity.
  • the housing comprises three cavities, the first and second conductive members, and the bypass diode are provided in the three cavities respectively.
  • the present invention provides at least one of following advantages: firstly, the present invention uses resilient clips in lieu of soldering process, hence avoids the inherent problem of soldering process, i.e. being time-consuming and resulting in a high production cost; in the meantime, the requirements for implementing the present invention are easy to be met, thus the manufacturing cost for the building integrated photovoltaic system is decreased; secondly, with the design of two or more cavities and corresponding covers, the housing of the junction module according to the present invention forms two or more units which can be uncovered separately so as to replace internal elements.
  • the present invention avoids the processing difficulty due to long and narrow shapes of the cavity and the cover, and thus improves the production efficiency of the junction module; in the other hand, by adopting the form of separate units which can be opened separately, the internal element of interest may be replaced individually with ease; thirdly, by using the resilient clips, a permanent connection between the solar cell assembly and the junction module is avoided, thus, compared with the conventional permanent connection, the disassembling of the solar cell assembly from the junction module is simplified, and the maintenance and inspection of the internal elements of the junction module, such as the diode, the resilient clips and connection terminals, can be carried out more conveniently.
  • Fig. 1 is a perspective view of a two-cavity junction module of a building integrated photovoltaic system according to an embodiment of the present invention, wherein the cover is in a close state;
  • Fig. 2 is an exploded perspective view of the two-cavity junction module shown in Fig. 1, wherein the junction module is uncovered to show position and structure relation of internal elements;
  • Fig. 3 is a perspective view of a three-cavity junction module of a building integrated photovoltaic system according to another embodiment of the present invention, wherein the junction module is in a closed state;
  • Fig. 4 is an exploded perspective view of the three-cavity junction module shown in Fig. 3, wherein the junction module is uncovered to show position and structure relation of internal elements; and
  • Fig. 5 is a schematic view showing that an electrical connection is formed between a connection terminal and a conductive member via a resilient clip in the above embodiments.
  • a junction module 100 of a building integrated photovoltaic system comprises a housing 1 having at least one opening 5, the at least one opening 5 being provided in a surface of the housing, such as a lower surface Ia shown in Figs.
  • the housing 1 comprises two cavities 11, 12, and wherein among said bypass diode 9, said first and second conductive members, at least one of which are provided separately in different cavities (11, 12 ).
  • the housing 1 could be made of insulating material.
  • the lugs 4 and the first and second conductive members are made of conductive material of such as copper, aluminum and the like. Referring to Fig. 2, in an exemplary embodiment, the first and second conductive members comprise first and second conductive rails 6 and 7, and connection conductors 19, 20 connected with the first and second conductive rails 6, 7.
  • the housing 1 is formed as a close end 14 or is formed as an opening end 13 having an outlet hole 13a for connecting directly or via a cable connector (not shown)with an external cable (not shown).
  • the housing 1 is substantially a hollow column whose left end is formed as the opening end 13 having the outlet hole 13a for connecting directly or via a cable connector with an external cable (not shown) , and whose right end is formed as the close end.
  • both ends of the housing 1 may be close ends (not shown) or opening ends (referring to Figs. 3 and 4) as required.
  • the external cable may be detachably and electrically connected, at the opening end 13, with at least one of the first and second conductive members (for example, at least one of the first and second conductive rails 6, 7 of the first and second conductive members) .
  • the opening end 13 is provided with a strong resilient clip 50.
  • the strong resilient clip 50 is substantially in a ⁇ shape, and is formed by a thin spring such as a steel spring sheet.
  • the ⁇ shaped clip 50 comprises a clip opening plate 51 having a clip opening 53, and an extending plate 52 which extends integrally from the clip opening plate 51 into the clip opening 53. Due to the resilience of the extending plate 52 itself, the extending plate 52 clamps a conductive wire, such as a core (not shown) of the external cable, which is inserted into the clip opening 53.
  • protrusions 63 and 73 are extended respectively from each of the free ends of the first and second conductive rails 6 and 7.
  • the core of the external cable is brought into contact with the protrusions 63, 73 of the first and second conductive rails 6 and 7, and the contacted protrusions and core are then inserted into the clip opening 53 of the resilient clip 50, in this case, the extending plate 52 clamps, by means of the resilience of the extending plate 52 itself, the protrusions 63, 73 and the core clipped within the clip opening 53, thus a reliable conductive connection between the core of the external cable and the conductive rail 6 is formed for conveying current therebetween.
  • the resilient clip 50 is not limited to the shape and structure described above( ⁇ shape), instead, it could be in any appropriate forms, for example, it could be the resilient clip 8 in Fig. 5, as long as the conductive rails and external cable (for example, the core of the external cable) are connected through clamping.
  • the conductive rails are connected with the cable by using the strong resilient clip
  • the present invention is not limited to that, for example, the connection may be achieved by using other detachable connection such as screw connection and the like, or by using non- detachable connection such as soldering and riveting and the like.
  • the joint of the at least one of the first and second conductive members and the strong resilient clip 50 is provided in one of the cavities, or, together with the joint of the lugs 4, is provided in one cavity (referring to Figs. 2 and 4), which facilitates checking and replacing in the future by opening the covers of the cavities.
  • each external cable could be connected in series with adjacent cell module via a connector or another connection cable so as to provide an increased output power.
  • the positive and negative electrode connection cables of the two outmost modules produce an output power at a predetermined voltage, which becomes the power that the whole solar cell module outputs.
  • the bypass diode 9 is arranged in a direction reverse to the direction of the current generated by the cell, so as to bypass the reverse bias current of the cell.
  • the cavities 11, 12 have openings 15, 16 respectively, and the junction module 100 further comprises two covers 2, 3 for closing the corresponding openings 15, 16 in a detachable manner.
  • the housing 1 comprises two cavities 11, 12, and one of the first and second conductive rails 6, 7, for instance, the conductive rail 7, and the bypass diode 9 are provided in one cavity 12, while the other conductive rail 7 of the first and second conductive rails 6, 7 is provided in the other cavity 11.
  • the junction module 100 further comprises seal rings 17, 18, each of which is provided between the cover 2(3) and the corresponding opening 15(16) so as to form a seal therebetween.
  • seal rings 17, 18 being provided between the covers 2, 3 and the corresponding openings 15, 16 so as to form seals therebetween, the negative effect caused by temperature and humidity on the performance of the internal elements of the junction module can be prevented.
  • a plurality of clasp legs 23, 33 are provided at the peripheries of the covers 2, 3 respectively, and correspondingly, a plurality of slots 24, 34 mating with the plurality of clasp legs 23, 33 are provided on the housing 1.
  • the clasp legs 23, 33 deform correspondingly so as to engage with the slots 24, 34 on the housing 1, in this case, the covers 2 and 3 are clasped closely to the housing 1 and thus the openings 15, 16 of the cavities 11, 12 of the housing 1 are closed or sealed.
  • Fig. 2 shows an embodiment of a clasp manner in which the covers 2, 3 are clasped to the housing 1, those skilled in the art will understand that the specific structure used by the clasp manner is not limited to this.
  • Fig. 5 shows another alternative connection structure.
  • the covers 2 and 3 each has a substantial inverse-U shape, and comprises a bottom 70, and two side walls 72 extending substantially in parallel.
  • lower parts of the side wall 72 are provided with protrusions 75, and the side wall 72 are provided at the outer side with recess parts 74.
  • a seal 17 is provided between the housing 1 and the recess parts 74 of the side wall 72 of the covers 2, 3 so as to form a sealing between the housing 1 and the covers 2, 3.
  • recess parts (not shown) corresponding to the recess parts 74 of the side wall 72 of the covers 2, 3 may also be provided on the housing 1 so that the seal 17 is arranged between the housing 1 and the covers 2, 3 stably and air tightly.
  • the seal 17 is arranged between the housing 1 and the side wall 72 of the covers 2, 3 in the above embodiment, the present invention is not limited to this.
  • the seal 17 may be provided at any suitable position between the covers 2, 3 and the openings 15, 16, as long as a seal is formed between the covers 2, 3 and the housing 1.
  • first and second connection conductors 19, 20 extend from and form integrally with the first and second conductive rails 6, 7 respectively.
  • the connection conductors 19, 20 may also be formed separately from the first and second conductive rails 6, 7, and then are electrically connected with the first and second conductive rails 6, 7.
  • connection conductors 19, 20 comprise two substantially flat opposite sides 201, 202; and a cross section of the resilient clip 8 substantially forms a triangle having an opening on top, thus the resilient clip 8 comprises a bottom wall 81 and two sidewalls 82, 83 extending from the bottom wall 81 at two ends of the bottom wall 81 at an acute angle.
  • the material of the resilient clip 8 is of predetermined elasticity, it may be metal material such as spring steel, or be non-metal material such as polyurethane plastics.
  • the two opposite sidewalls 82, 83 extend from the bottom wall 81 at two ends of the bottom wall 81 at an acute angle, the two opposite sidewalls 82, 83, under the resilient action of the resilient clip 8, may clamp components inserted therebetween, such as the connection conductor 19 (20) and the lug 4.
  • the lug 4 is provided between the resilient clip 8 and the connection conductor 19(20).
  • the lug 4 is flexible, and at least partially encloses the connection conductor 19 (20).
  • the resilient clip 8 clamps the lug 4
  • the two opposite sidewalls 82, 83 of the resilient clip 8 engage with the lug 4 and apply a bias force thereto so that a reliable electrical connection is formed between the lug 4 and the connection conductor 19 (20).
  • connection manner of the resilient clip 8, the connection conductor 19(20) and the lug 4 is described in connection with Fig. 5, the present invention is not limited to this, and the examplary embodiment showing the connection manner of the resilient clip 8, the connection conductor 19(20) and the lug 4 is only illustrative rather than limiting, and can be modified or amended variously, as long as the resilient clip 8 engages with the lug 4 and applies a bias force to the lug 4 so that a stable electrical connection is formed between the lug 4 and the connection conductor 19 (20).
  • the specific structures of the constituent components shown in the attached drawings of the present invention are illustrative rather than limiting.
  • the structure of the resilient clip 8 in a longitudinal direction thereof is not limited.
  • the present invention uses resilient clips in lieu of soldering process, which provides at least one of following advantages: firstly, the present hence avoids the inherent problem of soldering process, i.e. being time-consuming and resulting in a high production cost; in the meantime, the requirements for implementing the present invention are easy to be met, thus the manufacturing cost for the building integrated photovoltaic system is decreased; secondly, a permanent connection between the solar cell assembly and the junction module is avoided, thus, the disassembling of the solar cell assembly from the junction module is simplified, and the maintenance and inspection of the internal elements of the junction module, such as the diode, the resilient clips and connection terminals, can be carried out more conveniently.
  • the first and second conductive rails 6, 7 are further provided with a plurality of securing springs 61, 71, and two pins 91 , 92 of the bypass diode 9 are electrically connected with the first and second conductive rails 6, 7 by means of the securing springs 61, 71.
  • the bypass diode 9 may be mounted to or be removed from the first and second conductive rails 6, 7 conveniently.
  • the above securing springs 61, 71 are not the only way of connection, and the bypass diode 9 may also be connected with the first and second conductive rails 6 and 7 in other manners such as in a plug-in manner.
  • connection conductor 20 the securing spring 61 of the conductive rail 6, the securing spring 71 of the conductive rail 7, the bypass diode 9, one resilient clip 8 are accommodated in the cavity 12, while the connection conductor 19, other portion of the conductive rail 6, the other resilient clip 8 are accommodated in the cavity 11.
  • the securing spring 61 of the first conductive rail 6 is accommodated in the cavity 12, the present invention is not limited to this, for example, the securing spring 61 of the first conductive rail 6 may be accommodated in the cavity 11.
  • Fig. 3 is a perspective view of a three-cavity junction module of a building integrated photovoltaic system according to another embodiment of the present invention, wherein the junction module is in a closed state;
  • Fig. 4 is an exploded perspective view of the three-cavity junction module shown in Fig. 3, wherein the junction module is uncovered to show position and structure relation of internal elements.
  • the junction module of a building integrated photovoltaic system according to the second embodiment of the present invention is substantially the same as the junction module in the first embodiment, except the numbers of the cavities and the covers, and the manner of arranging the internal elements in the respective cavities. The difference between the second embodiment and the first embodiment will be described next, and the part similar to or the same as that in the first embodiment will be omitted herein.
  • the three-cavity junction module 300 comprises a housing 1 having at least one opening 5, the at least one opening 5 being provided in a surface of the housing, such as a lower surface Ia shown in Figs. 3-4, for inserting lugs 4 electrically connected with the positive and negative electrodes (not shown) of a solar cell panel; first and second conductive rails 6, 7, used as first and second conductive members, accommodated in the housing 1, the first and second conductive members being electrically connected with the lugs 4 respectively through resilient clips 8; and a bypass diode 9 which is connected between the first and second conductive members, wherein the housing 1 comprises three cavities 311, 312, 313, and at least one of the first and second conductive members, such as the first and second conductive rails 6, 7, and the bypass diode 9 are provided separately in the three different cavities 311, 312, 313 respectively, which differs from the solution in the first embodiment.
  • the cavities 311, 312, 313 have openings 315, 316, 317 respectively
  • the junction module 300 further comprises three covers 302, 303, 304 for detachably closing the corresponding openings 315, 316, 317 respectively.
  • the first and second conductive rails 6, 7 are further provided with a plurality of securing springs 61, 71, and two pins 91 , 92 of the bypass diode 9 are electrically connected with the first and second conductive rails 6, 7 by means of the securing springs 61, 71.
  • the first conductive rail 6, the lug 4 connected electrically with the first conductive rail 6, and the resilient clip 8 for clamping the first conductive rail 6 and the lug 4 are accommodated in the cavity 311;
  • the securing spring 61 connected with the first conductive rail 6, the securing spring 71 connected with the second conductive rail 7, and the bypass diode 9 are accommodated in the cavity 312;
  • the second conductive rail 7, the lug 4 connected electrically with the second conductive rail 7, and the resilient clip 8 for clamping the second conductive rail 7 and the corresponding lug 4 are accommodated in the cavity 313.
  • the present invention is not limited to this, for instance, the securing spring 61 of the first conductive rail 6 and the securing spring 71 of the second conductive rail 7 may be accommodated in the cavity 311 and the cavity 313 respectively.

Abstract

Disclosed is a junction module of a building integrated photovoltaic system, the junction module includes: a housing having at least one opening, the at least one opening being provided in a surface of the housing for inserting lugs electrically connected with the positive and negative electrodes of a solar cell panel; a first and a second conductive member accommodated in the housing, the first and second conductive members being electrically connected with the lugs respectively through first resilient clips; and a bypass diode which is connected between the first and second conductive members, wherein the housing comprises a plurality of cavities, and wherein among the bypass diode and the first, second conductive members,at least one of which are provided separately in different cavities. With two or more cavities and corresponding covers, the present invention avoids the processing difficulty caused by the long and narrow shape of the cavity, and thus improves the production efficiency of the junction module. In addition, by adopting the form of a plurality of separate units which can be opened separately, the internal element may be replaced individually with ease. [Fig. 2]

Description

JUNCTION MODULE OF BUILDING INTEGRATED PHOTOVOLTAIC SYSTEM
CROSS-REFERENCE OF RELATED APPLCATION This application claims the benefit of Chinese Patent Application No.
200910054093.5 filed before the State Intellectual Property Office of China on June 26, 2009, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Field of Invention
The present invention relates to the field of the building integrated photovoltaic (BIPV) technology, more particularly, to a junction module for building integration photovoltaic system.
Description of the Related Art
Solar energy is a kind of renewable energy source. Converting solar energy into electricity could save the resource of energy and mitigate increasing demands in power supply, and reduce the environment pollution as well. Therefore, this technology receives much attention and interest from the public. As a conventional way of utilizing the solar energy, the solar cell assembly (photovoltaic assembly) is mounted on the accomplished roof through a support, and a junction module to cooperate with the assembly is usually disposed at the backside of the solar cell assembly.
A new solar energy utilizing technology, called "building integrated photovoltaic technology (BIPV)" has been brought forward recently, in which the solar cell (photovoltaic) product is integrated into a part of the building, such as sunlight roof, window and glass curtain wall, hence the integrated parts could provide electricity while also provide the same functions of normal roof, window, and glass curtain walls.
In aforementioned BIPV technology, the connection terminal (lug) extending from the photovoltaic element of the solar cell assembly typically forms electrical connection with the conductive element of the junction module through soldering, and afterwards, a sealant is applied to achieve sealing.
However, in the above junction module, firstly, the electrical connection between the connection terminal (lug) from the solar cell assembly and the conductive element of the junction module is formed by soldering, which requires much operation time, decreases the reliability and rate of the qualified finished product, and thus results in high production cost, due to the complexity of the soldering; secondly, because the connection formed by soldering is a permanent connection, it is hard to remove the solar cell assembly from the junction module, and vice versa; thirdly, the above junction module is usually in a form of a long and narrow cavity, and a long and narrow cover is commonly provided to close the cavity for replacing or removing internal elements in the junction module, however, since the cavity and the cover are long and narrow, it is difficult to manufacture the junction module, which also results in low production efficiency, and since one long and narrow cover is used to close the whole cavity, it is not convenient to replace the internal elements of interest individually.
Summary of Invention
The present invention has been made to overcome or alleviate at least one aspect of the above mentioned disadvantages. Accordingly, an object of the present invention is to provide a junction module of a building integrated photovoltaic system which can be easily mounted and removed.
Another object of the present invention is to provide a reliable junction module of building integrated photovoltaic system which can be produced with high production efficiency. A further object of the present invention is to provide a junction module of a building integrated photovoltaic system, internal elements of interest inside which can be replaced conveniently.
According to one aspect of the present invention, a junction module of building integrated photovoltaic system is provided, the junction module comprises: a housing having at least one opening, the at least one opening being provided in a surface of the housing for inserting lugs electrically connected with the positive and negative electrodes of a solar cell panel; a first and a second conductive member accommodated in the housing, the first and second conductive members being electrically connected with the lugs respectively through first resilient clips; and a bypass diode connected between the first and second conductive members, wherein the housing comprises a plurality of cavities, and wherein among the bypass diode and the first, second conductive members, at least one of which is provided separately in different cavities. In an examplary embodiment, each of the plurality of cavities has an opening, and the junction module further comprises a plurality of covers each of which closes the corresponding opening in a detachable manner.
Advantageously, the junction module further comprises seal rings each provided between the cover and the corresponding opening so as to form a seal therebetween.
Specifically, at least one end of the housing is formed as a close end, or is formed as an opening end having an outlet hole for connecting with an external cable directly or via a cable connector.
In an examplary embodiment, the external cable may be electrically connected, at the opening end, with at least one of the first and second conductive members in a detachable manner.
Moreover, the junction module further comprises a second clip constructed to clip together a core of the external cable and at least one of the first and second conductive members, and the second clip together with the at least one of the first and second conductive members are provided together in one of the plurality of cavities.
In an examplary embodiment, the first and second conductive members comprise first and second conductive rails and connection conductors, the connection conductors comprising two opposite sides which are substantially flat surfaces; and the first resilient clip with a cross section which substantially forms a triangle having an opening on top, comprising a bottom wall and two sidewalls extending from the bottom wall at two sides of the bottom wall at an acute angle, wherein when the first resilient clip clamps the lug, the two opposite sidewalls of the clip contact with the lug and apply a bias force to the lug so that a stable electrical connection between the lug and the connection conductor is formed.
Advantageously, the first and second connection conductors extend from the first and second conductive rails respectively and form integrally with the corresponding conductive rails.
Advantageously, the first and second conductive rails are further provided with securing springs by means of which two pins of the bypass diode are electrically connected with the first and second conductive rails. Specifically, the above detachable manner is carried out by at least one of clasp connection, bolt connection, screw connection, stud connection and hinge connection. In an examplary embodiment, the housing comprises two cavities, and the bypass diode and one of the first and second conductors are provided in one cavity, while the other of the first and second conductive members is provided in the other cavity.
In another examplary embodiment, the housing comprises three cavities, the first and second conductive members, and the bypass diode are provided in the three cavities respectively.
With the above configuration, the present invention provides at least one of following advantages: firstly, the present invention uses resilient clips in lieu of soldering process, hence avoids the inherent problem of soldering process, i.e. being time-consuming and resulting in a high production cost; in the meantime, the requirements for implementing the present invention are easy to be met, thus the manufacturing cost for the building integrated photovoltaic system is decreased; secondly, with the design of two or more cavities and corresponding covers, the housing of the junction module according to the present invention forms two or more units which can be uncovered separately so as to replace internal elements. In one hand, the present invention avoids the processing difficulty due to long and narrow shapes of the cavity and the cover, and thus improves the production efficiency of the junction module; in the other hand, by adopting the form of separate units which can be opened separately, the internal element of interest may be replaced individually with ease; thirdly, by using the resilient clips, a permanent connection between the solar cell assembly and the junction module is avoided, thus, compared with the conventional permanent connection, the disassembling of the solar cell assembly from the junction module is simplified, and the maintenance and inspection of the internal elements of the junction module, such as the diode, the resilient clips and connection terminals, can be carried out more conveniently.
Brief Description of the Drawing
Fig. 1 is a perspective view of a two-cavity junction module of a building integrated photovoltaic system according to an embodiment of the present invention, wherein the cover is in a close state; Fig. 2 is an exploded perspective view of the two-cavity junction module shown in Fig. 1, wherein the junction module is uncovered to show position and structure relation of internal elements;
Fig. 3 is a perspective view of a three-cavity junction module of a building integrated photovoltaic system according to another embodiment of the present invention, wherein the junction module is in a closed state;
Fig. 4 is an exploded perspective view of the three-cavity junction module shown in Fig. 3, wherein the junction module is uncovered to show position and structure relation of internal elements; and Fig. 5 is a schematic view showing that an electrical connection is formed between a connection terminal and a conductive member via a resilient clip in the above embodiments.
Detailed Description of Preferred Embodiments
Preferred embodiments of the present invention will be described hereinafter in detail with reference to the attached drawings, wherein the like reference numerals refer to the like elements throughout the specification. These embodiments should not be construed as being limited to the embodiment set forth herein, rather for illustrative purpose.
FIRST EMBODIMENT Referring to Figs. 1-2 and 5, a junction module 100 of a building integrated photovoltaic system according to an embodiment of the invention comprises a housing 1 having at least one opening 5, the at least one opening 5 being provided in a surface of the housing, such as a lower surface Ia shown in Figs. 1-2, for inserting lugs 4 electrically connected with the positive and negative electrodes (not shown) of a solar cell panel; a first and a second conductive member accommodated in the housing 1, the first and second conductive members being electrically connected with the lugs 4 respectively through resilient clips 8; and a bypass diode 9 which is connected between the first and second conductive members, wherein the housing 1 comprises two cavities 11, 12, and wherein among said bypass diode 9, said first and second conductive members, at least one of which are provided separately in different cavities (11, 12 ). In above junction module, the housing 1 could be made of insulating material. The lugs 4 and the first and second conductive members are made of conductive material of such as copper, aluminum and the like. Referring to Fig. 2, in an exemplary embodiment, the first and second conductive members comprise first and second conductive rails 6 and 7, and connection conductors 19, 20 connected with the first and second conductive rails 6, 7.
Referring to Figs. 1, 2, at least one end of the housing 1 is formed as a close end 14 or is formed as an opening end 13 having an outlet hole 13a for connecting directly or via a cable connector (not shown)with an external cable (not shown). Specifically, as shown in Figs. 1 and 2, the housing 1 is substantially a hollow column whose left end is formed as the opening end 13 having the outlet hole 13a for connecting directly or via a cable connector with an external cable (not shown) , and whose right end is formed as the close end. However, the present invention is not limited to this, for example, both ends of the housing 1 may be close ends (not shown) or opening ends (referring to Figs. 3 and 4) as required.
Moreover, the external cable may be detachably and electrically connected, at the opening end 13, with at least one of the first and second conductive members (for example, at least one of the first and second conductive rails 6, 7 of the first and second conductive members) . Referring to Figs. 2 and 4, in an examplary embodiment, the opening end 13 is provided with a strong resilient clip 50. As shown in Figs. 2 and 4, the strong resilient clip 50 is substantially in a α shape, and is formed by a thin spring such as a steel spring sheet. In an examplary embodiment, the α shaped clip 50 comprises a clip opening plate 51 having a clip opening 53, and an extending plate 52 which extends integrally from the clip opening plate 51 into the clip opening 53. Due to the resilience of the extending plate 52 itself, the extending plate 52 clamps a conductive wire, such as a core (not shown) of the external cable, which is inserted into the clip opening 53.
In the embodiments shown in Figs. 2 and 4, protrusions 63 and 73 are extended respectively from each of the free ends of the first and second conductive rails 6 and 7. When the external cable is connected with the conductive rails 6, 7, the core of the external cable is brought into contact with the protrusions 63, 73 of the first and second conductive rails 6 and 7, and the contacted protrusions and core are then inserted into the clip opening 53 of the resilient clip 50, in this case, the extending plate 52 clamps, by means of the resilience of the extending plate 52 itself, the protrusions 63, 73 and the core clipped within the clip opening 53, thus a reliable conductive connection between the core of the external cable and the conductive rail 6 is formed for conveying current therebetween. By using the above non- soldering manner, the mounting and replacement of the core of the external cable are simple. Please note that the resilient clip 50 is not limited to the shape and structure described above( α shape), instead, it could be in any appropriate forms, for example, it could be the resilient clip 8 in Fig. 5, as long as the conductive rails and external cable (for example, the core of the external cable) are connected through clamping. Further, though in the above embodiments the conductive rails are connected with the cable by using the strong resilient clip, the present invention is not limited to that, for example, the connection may be achieved by using other detachable connection such as screw connection and the like, or by using non- detachable connection such as soldering and riveting and the like. No matter what cable connection manner is used, the joint of the at least one of the first and second conductive members and the strong resilient clip 50 is provided in one of the cavities, or, together with the joint of the lugs 4, is provided in one cavity (referring to Figs. 2 and 4), which facilitates checking and replacing in the future by opening the covers of the cavities.
Further, each external cable could be connected in series with adjacent cell module via a connector or another connection cable so as to provide an increased output power. The positive and negative electrode connection cables of the two outmost modules produce an output power at a predetermined voltage, which becomes the power that the whole solar cell module outputs. The bypass diode 9 is arranged in a direction reverse to the direction of the current generated by the cell, so as to bypass the reverse bias current of the cell.
Referring to Fig. 2, the cavities 11, 12 have openings 15, 16 respectively, and the junction module 100 further comprises two covers 2, 3 for closing the corresponding openings 15, 16 in a detachable manner. Referring to Fig. 2, in an examplary embodiment, the housing 1 comprises two cavities 11, 12, and one of the first and second conductive rails 6, 7, for instance, the conductive rail 7, and the bypass diode 9 are provided in one cavity 12, while the other conductive rail 7 of the first and second conductive rails 6, 7 is provided in the other cavity 11.
In a preferred embodiment, the junction module 100 further comprises seal rings 17, 18, each of which is provided between the cover 2(3) and the corresponding opening 15(16) so as to form a seal therebetween. With the seal rings 17, 18 being provided between the covers 2, 3 and the corresponding openings 15, 16 so as to form seals therebetween, the negative effect caused by temperature and humidity on the performance of the internal elements of the junction module can be prevented.
Specifically, referring to Fig. 2, a plurality of clasp legs 23, 33 are provided at the peripheries of the covers 2, 3 respectively, and correspondingly, a plurality of slots 24, 34 mating with the plurality of clasp legs 23, 33 are provided on the housing 1. Under the action of the external force applied to the covers 2, 3 by an operator, the clasp legs 23, 33 deform correspondingly so as to engage with the slots 24, 34 on the housing 1, in this case, the covers 2 and 3 are clasped closely to the housing 1 and thus the openings 15, 16 of the cavities 11, 12 of the housing 1 are closed or sealed. Though Fig. 2 shows an embodiment of a clasp manner in which the covers 2, 3 are clasped to the housing 1, those skilled in the art will understand that the specific structure used by the clasp manner is not limited to this.
Fig. 5 shows another alternative connection structure. Referring Fig. 5, the covers 2 and 3 each has a substantial inverse-U shape, and comprises a bottom 70, and two side walls 72 extending substantially in parallel. Referring to Fig. 5, lower parts of the side wall 72 are provided with protrusions 75, and the side wall 72 are provided at the outer side with recess parts 74. Preferably, a seal 17 is provided between the housing 1 and the recess parts 74 of the side wall 72 of the covers 2, 3 so as to form a sealing between the housing 1 and the covers 2, 3. Further preferably, recess parts (not shown) corresponding to the recess parts 74 of the side wall 72 of the covers 2, 3 may also be provided on the housing 1 so that the seal 17 is arranged between the housing 1 and the covers 2, 3 stably and air tightly.
Though the seal 17 is arranged between the housing 1 and the side wall 72 of the covers 2, 3 in the above embodiment, the present invention is not limited to this. The seal 17 may be provided at any suitable position between the covers 2, 3 and the openings 15, 16, as long as a seal is formed between the covers 2, 3 and the housing 1.
Though the above embodiments illustrate the clasping structure and the alternative connection structures, the present invention is not limited to this. The covers 2, 3 may be connected to the housing to seal the openings 15, 16 in other alternative manners, such as bolt connection, screw connection, stud connection and hinge connection. Referring to Fig. 2 again, in a preferred embodiment, first and second connection conductors 19, 20 extend from and form integrally with the first and second conductive rails 6, 7 respectively. Obviously, the connection conductors 19, 20 may also be formed separately from the first and second conductive rails 6, 7, and then are electrically connected with the first and second conductive rails 6, 7. Referring to Fig. 5, the connection conductors 19, 20 comprise two substantially flat opposite sides 201, 202; and a cross section of the resilient clip 8 substantially forms a triangle having an opening on top, thus the resilient clip 8 comprises a bottom wall 81 and two sidewalls 82, 83 extending from the bottom wall 81 at two ends of the bottom wall 81 at an acute angle. The material of the resilient clip 8 is of predetermined elasticity, it may be metal material such as spring steel, or be non-metal material such as polyurethane plastics. Because the two opposite sidewalls 82, 83 extend from the bottom wall 81 at two ends of the bottom wall 81 at an acute angle, the two opposite sidewalls 82, 83, under the resilient action of the resilient clip 8, may clamp components inserted therebetween, such as the connection conductor 19 (20) and the lug 4.
Referring to Fig. 5, the lug 4 is provided between the resilient clip 8 and the connection conductor 19(20). In a preferable embodiment, the lug 4 is flexible, and at least partially encloses the connection conductor 19 (20). Thus, when the resilient clip 8 clamps the lug 4, the two opposite sidewalls 82, 83 of the resilient clip 8 engage with the lug 4 and apply a bias force thereto so that a reliable electrical connection is formed between the lug 4 and the connection conductor 19 (20).
Though the connection manner of the resilient clip 8, the connection conductor 19(20) and the lug 4 is described in connection with Fig. 5, the present invention is not limited to this, and the examplary embodiment showing the connection manner of the resilient clip 8, the connection conductor 19(20) and the lug 4 is only illustrative rather than limiting, and can be modified or amended variously, as long as the resilient clip 8 engages with the lug 4 and applies a bias force to the lug 4 so that a stable electrical connection is formed between the lug 4 and the connection conductor 19 (20). In addition, the specific structures of the constituent components shown in the attached drawings of the present invention are illustrative rather than limiting. For example, as for the resilient clip 8, as long as the cross section thereof is suitable for engaging with the lug 4 and applying a bias force to the lug 4 so that a stable electrical connection between the lug 4 and the connection conductor 19 (20) is obtained, the structure of the resilient clip 8 in a longitudinal direction thereof (referring to Fig. 4) is not limited.
The present invention uses resilient clips in lieu of soldering process, which provides at least one of following advantages: firstly, the present hence avoids the inherent problem of soldering process, i.e. being time-consuming and resulting in a high production cost; in the meantime, the requirements for implementing the present invention are easy to be met, thus the manufacturing cost for the building integrated photovoltaic system is decreased; secondly, a permanent connection between the solar cell assembly and the junction module is avoided, thus, the disassembling of the solar cell assembly from the junction module is simplified, and the maintenance and inspection of the internal elements of the junction module, such as the diode, the resilient clips and connection terminals, can be carried out more conveniently.
Referring to Fig. 2, in a preferred embodiment, the first and second conductive rails 6, 7 are further provided with a plurality of securing springs 61, 71, and two pins 91 , 92 of the bypass diode 9 are electrically connected with the first and second conductive rails 6, 7 by means of the securing springs 61, 71. By providing the above securing springs 61, 71, the bypass diode 9 may be mounted to or be removed from the first and second conductive rails 6, 7 conveniently. However, the above securing springs 61, 71 are not the only way of connection, and the bypass diode 9 may also be connected with the first and second conductive rails 6 and 7 in other manners such as in a plug-in manner. Alternatively, in the embodiment in which a plurality of securing springs 61, 71 are further provided, the connection conductor 20, the securing spring 61 of the conductive rail 6, the securing spring 71 of the conductive rail 7, the bypass diode 9, one resilient clip 8 are accommodated in the cavity 12, while the connection conductor 19, other portion of the conductive rail 6, the other resilient clip 8 are accommodated in the cavity 11. Though in the above embodiments, the securing spring 61 of the first conductive rail 6 is accommodated in the cavity 12, the present invention is not limited to this, for example, the securing spring 61 of the first conductive rail 6 may be accommodated in the cavity 11.
SECOND EMBODIMENT
Fig. 3 is a perspective view of a three-cavity junction module of a building integrated photovoltaic system according to another embodiment of the present invention, wherein the junction module is in a closed state; Fig. 4 is an exploded perspective view of the three-cavity junction module shown in Fig. 3, wherein the junction module is uncovered to show position and structure relation of internal elements. The junction module of a building integrated photovoltaic system according to the second embodiment of the present invention is substantially the same as the junction module in the first embodiment, except the numbers of the cavities and the covers, and the manner of arranging the internal elements in the respective cavities. The difference between the second embodiment and the first embodiment will be described next, and the part similar to or the same as that in the first embodiment will be omitted herein. Referring to Figs. 3 and 4, the three-cavity junction module 300 comprises a housing 1 having at least one opening 5, the at least one opening 5 being provided in a surface of the housing, such as a lower surface Ia shown in Figs. 3-4, for inserting lugs 4 electrically connected with the positive and negative electrodes (not shown) of a solar cell panel; first and second conductive rails 6, 7, used as first and second conductive members, accommodated in the housing 1, the first and second conductive members being electrically connected with the lugs 4 respectively through resilient clips 8; and a bypass diode 9 which is connected between the first and second conductive members, wherein the housing 1 comprises three cavities 311, 312, 313, and at least one of the first and second conductive members, such as the first and second conductive rails 6, 7, and the bypass diode 9 are provided separately in the three different cavities 311, 312, 313 respectively, which differs from the solution in the first embodiment.
Referring to Figs. 3 and 4, the cavities 311, 312, 313 have openings 315, 316, 317 respectively, and the junction module 300 further comprises three covers 302, 303, 304 for detachably closing the corresponding openings 315, 316, 317 respectively. Referring to Fig. 4, in an examplary embodiment, preferably, the first and second conductive rails 6, 7 are further provided with a plurality of securing springs 61, 71, and two pins 91 , 92 of the bypass diode 9 are electrically connected with the first and second conductive rails 6, 7 by means of the securing springs 61, 71. In this case, alternatively, the first conductive rail 6, the lug 4 connected electrically with the first conductive rail 6, and the resilient clip 8 for clamping the first conductive rail 6 and the lug 4 are accommodated in the cavity 311; the securing spring 61 connected with the first conductive rail 6, the securing spring 71 connected with the second conductive rail 7, and the bypass diode 9 are accommodated in the cavity 312; the second conductive rail 7, the lug 4 connected electrically with the second conductive rail 7, and the resilient clip 8 for clamping the second conductive rail 7 and the corresponding lug 4 are accommodated in the cavity 313. Though in the above embodiment, the securing spring 61 of the first conductive rail 6 and the securing spring 71 of the second conductive rail 7 are accommodated in the cavity 312, the present invention is not limited to this, for instance, the securing spring 61 of the first conductive rail 6 and the securing spring 71 of the second conductive rail 7 may be accommodated in the cavity 311 and the cavity 313 respectively.
With the configuration of three cavities 311, 312, 313, the possibility and convenience for opening the covers so as to replace the internal elements such as the diode, the resilient clip, the lug, is further i. Although the general inventive concept of present invention is described in conjunction with the embodiments of a two-cavity junction module and a three-cavity junction module, the present invention is not limited to this. Based on the above embodiments, those skilled in the art will understand that a junction module having more than three cavities may be provided to further improve the convenience for maintenance and replacement of the internal elements accommodated in each cavity.
It can be known from above that because of the design that two or more cavities and two or more corresponding covers are used in the present invention, two or more units, which can be uncovered separately to replace the internal elements, are formed at the housing of the junction module, one hand, the above design avoids the processing difficulty due to long and narrow shapes of the cavity and the cover, and thus improves the production efficiency of the junction module; the other hand, by using the separate units can be detached separately, the internal element be replaced individually with ease.
Although the various embodiments of present invention have been described in conjunction with the drawings, those skilled in the art shall recognize that these embodiments disclosed in the drawings are illustration of the manners that present invention may be practiced. It is to be understood that the present invention is not limited to these specific embodiments. Similarly, the terms used in the description for indicating an orientation, such as, "upper", "lower", "upper surface", "lower surface" etc., though correspond to the upper or lower portion of the figures concerned, but they may refer to any orientations, which if viewed from a contrary angle or lateral side, might correspond to "lower", "upper" or "left" and "right".

Claims

1. A junction module of a building integrated photovoltaic system, comprising: a housing having at least one opening, the at least one opening being provided in a surface of the housing for inserting lugs electrically connected with the positive and negative electrodes of a solar cell panel; a first and a second conductive member accommodated in the housing, the first and second conductive members being electrically connected with the lugs respectively through first resilient clips; and a bypass diode connected between the first and second conductive members, wherein the housing comprises a plurality of cavities, and wherein among the bypass diode and the first, second conductive members, at least one of which are provided separately in different cavities.
2. The junction module according to claim 1, wherein: each of the plurality of cavities has an opening, and the junction module further comprises a plurality of covers, each of which closes the corresponding opening in a detachable manner.
3. The junction module according to claim 2, further comprising: seal rings, each provided between the cover and the corresponding opening so as to form a seal therebetween.
4. The junction module according to claim 1 , wherein: at least one end of the housing is formed as a close end or is formed as an opening end having an outlet hole for connecting with an external cable directly or via a cable connector.
5. 5. The junction module according to claim 4, wherein the external cable is electrically connected, at the opening end, with at least one of the first and second conductive members in a detachable manner.
6. The junction module according to claim 5, further comprising: a second clip constructed to clip together the core of the external cable and at least one of the first and second conductive members, wherein the second clip together with the at least one of the first and second conductive members are provided in one of the plurality of cavities.
7. The junction module according to claim 1, wherein the first and second conductive members comprise first and second conductive rails and connection conductors, the connection conductors comprising two opposite sides which have substantially flat surfaces; and the first resilient clip, with a cross section which substantially forms a triangle having an opening on top, comprises a bottom wall and two sidewalls extending from the bottom wall at two sides of the bottom wall at an acute angle, wherein when the first resilient clip clamps the lug, the two opposite sidewalls of the clip contact with the lug and apply a bias force to the lug so that a stable electrical connection between the lug and the connection conductor is formed.
8. The junction module according to claim 7, wherein the first and second connection conductors extend from the first and second conductive rails respectively and form integrally with the corresponding conductive rails.
9. The junction module according to claim 8, wherein the first and second conductive rails are further provided with securing springs by means of which two pins of the bypass diode are electrically connected with the first and second conductive rails.
10. The junction module according to claim 2, wherein: the above detachable manner is carried out by clasp connection, bolt connection, screw connection, stud connection or hinge connection.
11. The junction module according to claim 1 , wherein the housing comprises two cavities, and the bypass diode and one of the first and second conductors are provided in one cavity, while the other of the first and second conductive members is provided in the other cavity.
12. The junction module according to claim 1, wherein the housing comprises three cavities, the first, the second conductive members, and the bypass diode are provided in the three cavities respectively.
PCT/IB2010/052792 2009-06-26 2010-06-21 Junction module of building integrated photovoltaic system WO2010150173A1 (en)

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